Disc type rotary intelligent wire plugging device and intelligent wire plugging method

Abstract

The invention provides a disc-type rotary intelligent wire plugging device and an intelligent wire plugging method, and belongs to the field of automobile intelligent manufacturing, the disc-type rotary intelligent wire plugging device comprises a manipulator wire plugging mechanism, a multi-station turntable mechanism, a wire plugging position jacking and rotating mechanism, a material taking jacking mechanism, an error-proofing visual detection mechanism and a rotary wire plugging controller; the multi-station turntable mechanism is used for rotationally providing different layers of wire plugging stations and receiving flat wire hairpins provided by the manipulator wire plugging mechanism; the wire inserting position jacking rotating mechanism and the material taking jacking mechanism are arranged below the multi-station rotating disc mechanism and used for rotating to assist wire inserting and jacking material taking. The error-proofing visual detection mechanism monitors the card issuing line type and position of the flat wire, and real-time judgment and feedback of wrong insertion and missing insertion are realized; automatic wire plugging is combined with real-time monitoring, the wire plugging quality and the motor performance are ensured, and the method can be popularized and applied in the field of driving motor manufacturing of new energy automobiles or other motor manufacturing fields needing efficient and accurate wire plugging.

Description

Technical Field

[0001] The present invention belongs to the field of automobile intelligent manufacturing, and in particular relates to a disc-type rotating intelligent wiring plugging device and an intelligent wiring plugging method. Background Art

[0002] With the global energy crisis and the increasing awareness of environmental protection, the new energy vehicle industry is booming at an unprecedented speed. As one of the core components of new energy vehicles, the performance of the drive motor directly affects the power, economy and range of the vehicle.

[0003] In recent years, flat wire motors have gradually become the first choice for new energy vehicle drive motors due to their high power density, high efficiency, low noise and good heat dissipation performance. However, in the manufacturing process of flat wire motors, the stator wire insertion link is a technical difficulty. The traditional manual wire insertion method has problems such as low production efficiency, difficulty in ensuring the slot full rate, and easy scratching of the enameled wire, which not only increases the manufacturing cost, but also affects the performance and reliability of the motor. Therefore, the development of an efficient and precise automatic wire insertion device is of great significance to improving the manufacturing quality and production efficiency of flat wire motors. Summary of the invention

[0004] In order to overcome the deficiencies of the prior art, the purpose of the present invention is to develop a disc-type rotating intelligent wiring plugging device and an intelligent wiring plugging method for an electric drive flat wire stator of a new energy vehicle, so as to solve the stator wiring plugging problem in the manufacturing process of a flat wire motor.

[0005] A disc-type rotating intelligent wire plugging device comprises a manipulator wire plugging mechanism, a multi-station turntable mechanism, a wire plugging position lifting and rotating mechanism, a material picking and lifting mechanism, an error-proofing visual detection mechanism and a rotating wire plugging controller; the manipulator wire plugging mechanism is used to clamp flat wire cards of different specifications and transport them to the top of the wire plugging position of the multi-station turntable mechanism; the multi-station turntable mechanism is used to rotate to provide wire plugging stations of different layers and receive flat wire cards provided by the manipulator wire plugging mechanism; the wire plugging position lifting and rotating mechanism and the material picking and lifting mechanism are arranged below the multi-station turntable mechanism, and are used to rotate and assist the upper wire plugging station in plugging or lift it to facilitate full-layer material picking; the error-proofing visual detection mechanism is arranged on the periphery of the multi-station turntable mechanism, and is used to monitor the line type and position of the flat wire card, so as to realize real-time judgment and feedback of wrong plugging and missed plugging.

[0006] Furthermore, the robot wire insertion mechanism includes a multi-axis robot arm, a wire insertion lifting rod and a flat wire clamp, and the flat wire clamp is installed to the end of the vertically arranged wire insertion lifting rod.

[0007] Furthermore, the multi-station turntable mechanism includes a turntable rotating seat, a multi-station turntable body, a plurality of assumed sub-tools and a tooling line taking and positioning assembly; a rotating switching station is fixed to the turntable rotating seat and driven at the lower middle part of the multi-station turntable body, and a plurality of the assumed sub-tools are arranged on the line insertion station of the multi-station turntable body and are controllably positioned by the tooling line taking and positioning assembly.

[0008] Further, it is assumed that the sub-tooling includes a positioning slot bottom plate that slides up and down in the wire plug-in cage frame, a push plate and a through slot top plate with radially evenly distributed slots and positioning fins; the positioning slot bottom plate and the through slot top plate are supported and connected by an upper support column group, and the push plate is arranged between the positioning slot bottom plate and the through slot top plate along the upper support column group, and multiple wire plug-in lifting rods that pass through the positioning slot bottom plate are connected at the bottom of the push plate; two rotating plates are connected from the bottom of the wire plug-in cage frame to the bottom surface of the positioning slot bottom plate above.

[0009] Furthermore, the lower ends of the plurality of wire-inserting jacking rods are arranged on a wire-inserting jacking plate, which matches the material-taking jacking mechanism below.

[0010] Furthermore, the plug-in position lifting and rotating mechanism includes a lifting and rotating gantry, a lifting plate, a lifting drive, a rotating drive, a rotating adapter and a rotating profiling member; the four corners of the bottom surface of the lifting plate are slidably installed above the crossbeam plate of the lifting and rotating gantry through a guide column assembly, and the lifting rods of the two lifting drives pass through the bottom of the crossbeam plate of the lifting and rotating gantry and are connected to the two ends of the bottom surface of the lifting plate. The outer casing of the rotating drive is fixed to the lifting plate, and the end of the rotating shaft of the rotating drive is connected to the rotating adapter, thereby driving the rotating adapter and the rotating profiling member to rotate as designed.

[0011] Furthermore, the material picking and lifting mechanism comprises a material picking and lifting gantry, a material picking and lifting driver and a lifting head, and the lifting head is arranged at the end of a lifting rod of the material picking and lifting driver which is telescopically extended vertically upward.

[0012] Furthermore, the error-proofing visual detection mechanism includes a light curtain sensing detection component and an optical camera detection component, wherein the light curtain sensing detection component is horizontally arranged toward the wire insertion position of the multi-station turntable mechanism, and the optical camera detection component is arranged above the middle of the multi-station turntable mechanism and obliquely downward toward the wire insertion position.

[0013] The present invention also provides an intelligent wire plugging method, which includes: S1, a manipulator clamps a flat wire hairpin and transfers it to above the wire plugging position, and a turntable rotates to transfer an assumed sub-tooling to the wire plugging position; S2, the manipulator descends to insert the flat wire hairpin into the assumed sub-tooling; S3, the manipulator rises and clamps the next flat wire hairpin; S4, the assumed sub-tooling itself rotates step by step to the next empty wire slot, and the manipulator transfers the clamped flat wire hairpin to above the wire plugging position; S5, repeating S2-S4 until a circle is fully plugged; S6, the turntable rotates, and the station where a circle of assumed sub-tooling is fully plugged is transferred to the wire taking station, and another empty assumed sub-tooling is transferred to the wire plugging position, and a new round of wire plugging is carried out.

[0014] Compared with the prior art, the beneficial effects of the present invention are: the disc-type rotating intelligent wire insertion device of the present application adopts advanced automation technology to realize the automatic grasping, arrangement and insertion of flat wire coils, ensuring the accurate position and close arrangement of the coils in the stator slots; the system will also monitor and feedback the status of the enameled wire during the wire insertion process in real time to avoid scratches and damage, ensure that the wire insertion quality and motor performance meet the design requirements, and can be promoted and applied in the manufacturing of drive motors for new energy vehicles or other motor manufacturing fields that require efficient and precise wire insertion. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 A schematic diagram of a disc-type rotating intelligent plug-in device of the present invention; Figure 2 This is a schematic diagram of the wire insertion mechanism of the robot; Figure 3 It is a schematic diagram of a multi-station turntable mechanism; Figure 4 It is a schematic diagram of the hypothetical sub-tooling; Figure 5 The figure is a schematic diagram of the decomposition of the hypothetical sub-tool; Figure 6 A schematic diagram of a push plate; Figure 7 It is a schematic diagram of the lifting and rotating mechanism at the wire insertion position; Figure 8 This is a schematic diagram of the material lifting mechanism.

[0016] In the figure, 10. Robotic wire insertion mechanism; 11. Multi-axis robotic arm; 12. Wire insertion lifting rod; 13. Flat wire clamp; 20. Multi-station turntable mechanism; 21. Turntable rotating seat; 22. Multi-station turntable body; 23. Assume sub-tooling; 24. Tooling line positioning assembly; 231, wire insertion cage; 2311, cage top ring; 2312, cage bottom ring; 2313, cage support pole; 2314, positioning pin; 232, positioning groove bottom plate; 233, push plate; 234, through-slot top plate; 235, upper support column group; 236, wire insertion lifting rod; 237, wire insertion lifting plate; 238, rotating plate; 239, wire removal positioning block; 2310, wire insertion side baffle; 30. Lifting and rotating mechanism at the plug-in position; 31. Lifting and rotating gantry; 32. Lifting plate; 33. Lifting drive; 34. Rotating drive; 35. Rotating adapter; 36. Rotating profiling member; 37. Guide column assembly; 40. Material lifting mechanism; 41. Material lifting gantry; 42. Material lifting driver; 43. Lifting head; 51. Light curtain sensing detection component; 52. Optical camera detection component. DETAILED DESCRIPTION

[0017] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0018] A disc-type rotating intelligent plug-in device, see Figure 1-Figure 8 The disc-type rotating intelligent wire insertion device includes a manipulator wire insertion mechanism 10, a multi-station turntable mechanism 20, a wire insertion position lifting and rotating mechanism 30, a material picking and lifting mechanism 40, an error-proofing visual detection mechanism and a rotating wire insertion controller.

[0019] The robot wire insertion mechanism 10 is used to clamp flat wire cards of different specifications and transport them to the top of the wire insertion position of the multi-station turntable mechanism 20; the multi-station turntable mechanism 20 is used to rotate to provide wire insertion positions on different layers and receive the flat wire cards provided by the robot wire insertion mechanism 10; the wire insertion position lifting and rotating mechanism 30 and the material picking and lifting mechanism 40 are arranged below the multi-station turntable mechanism 20, and are used to rotate and assist the upper wire insertion position in plugging or lifting to facilitate full-layer material picking; the error-proofing visual detection mechanism is arranged on the periphery of the multi-station turntable mechanism 20, and is used to monitor the line type and position of the flat wire card, and realize real-time judgment and feedback of wrong insertion and missed insertion.

[0020] Among them, see Figure 2 The manipulator wire insertion mechanism 10 includes a multi-axis manipulator arm 11, a wire insertion lifting rod 12 and a flat wire clamp 13, and the flat wire clamp 13 is installed to the end of the vertically arranged wire insertion lifting rod 12.

[0021] The multi-axis robot arm 11 adopts a four-axis robot arm, and the wire insertion lifting rod 12 is arranged on the end shaft of the four-axis robot arm in the form of a screw rod or a threaded rod, and is driven to lift by the four-axis robot arm, thereby realizing the pressing down and lifting of the flat wire clamp 13. The four-axis robot arm can rotate horizontally, and the flat wire clamp 13 is lifted and transferred to the top of the wire insertion position of the multi-station turntable mechanism 20 after clamping the flat wire for carding, and then pressed down and inserted the wire in sequence.

[0022] Among them, see Figure 3-Figure 6 The multi-station turntable mechanism 20 includes a turntable rotating seat 21, a multi-station turntable body 22, a plurality of assumed sub-tooling 23 and a tooling line positioning assembly 24; a rotating switching station fixed to the turntable rotating seat 21 and driven at the lower middle part of the multi-station turntable body 22, and a plurality of the assumed sub-tooling 23 are arranged on the line insertion station of the multi-station turntable body 22, and are controllably positioned by the tooling line positioning assembly 24.

[0023] Assume that the sub-tooling 23 includes a positioning slot chassis 232 that slides up and down in the wire insertion cage 231, a push plate 233 with radially evenly distributed slots and positioning fins, and a through slot top plate 234; the positioning slot chassis 232 and the through slot top plate 234 are supported and connected by an upper support column group 235, and the push plate 233 is slidably arranged between the positioning slot chassis 232 and the through slot top plate 234 along the upper support column group 235, and a plurality of wire insertion lifting rods 236 that pass through the positioning slot chassis 232 are connected at the bottom of the push plate 233; two rotating plates 238 are connected from the bottom of the wire insertion cage 231 to the bottom surface of the positioning slot chassis 232 above.

[0024] The lower ends of the plurality of wire insertion lifting rods 236 are arranged on a wire insertion lifting plate 237, which matches the material taking lifting mechanism 40 below.

[0025] A wire taking positioning block 239 is also provided on the outer peripheral surface of the positioning groove bottom plate 232, and a positioning pin hole is radially provided in the wire taking positioning block 239.

[0026] The wire insertion cage 231 includes a cage top ring 2311, a cage bottom ring 2312 and a cage support pole 2313. A positioning pin 2314 is arranged on the periphery of the cage bottom ring 2312. The positioning pin 2314 and the tooling wire taking positioning assembly 24 drive the positioning pin to insert into or disengage from the pin hole of the wire taking positioning block 239.

[0027] A plurality of radially evenly distributed wire-insertion side baffles 2310 are also arranged between the positioning groove bottom plate 232 and the through groove top plate 234 , and the wire-insertion side baffles 2310 pass through radially evenly distributed slots of the push plate 233 of the positioning fin plate.

[0028] Among them, see Figure 7The plug-in position lifting and rotating mechanism 30 includes a lifting and rotating gantry 31, a lifting plate 32, a lifting driver 33, a rotating driver 34, a rotating adapter 35 and a rotating profiling member 36; the four corners of the bottom surface of the lifting plate 32 are slidably installed above the crossbeam plate of the lifting and rotating gantry 31 through a guide column assembly 37, and the lifting rods of the two lifting drivers 33 pass through the bottom of the crossbeam plate of the lifting and rotating gantry 31 and are connected to the two ends of the bottom surface of the lifting plate 32. The outer shell of the rotating driver 34 is fixed to the lifting plate 32, and the end of the rotating shaft of the rotating driver 34 is connected to the rotating adapter 35, thereby driving the rotating adapter 35 and the rotating profiling member 36 to rotate as designed.

[0029] The bottom of the rotating plate 238 is provided with driving notches such as arc grooves and V-shaped grooves, and the shape of the rotating profiling member 36 is adapted to the driving notches, for example, in the form of an axis or an axis and a bearing roller, and the rotating plate 238 with an arc groove as the driving notch is matched with it.

[0030] Of course, the mechanism is also provided with lifting and rotating limiters, such as rotation sensors, etc., to facilitate the intelligent control of lifting and rotating.

[0031] Among them, see Figure 8 The material picking and lifting mechanism 40 includes a material picking and lifting gantry 41, a material picking and lifting driver 42 and a lifting head 43. The lifting head 43 is arranged at the end of a lifting rod of the material picking and lifting driver 42 which is telescopically extended upward.

[0032] Among them, see Figure 1 The error-proofing visual detection mechanism includes a light curtain sensing detection component 51 and an optical camera detection component 52, wherein the light curtain sensing detection component 51 is horizontally arranged toward the wire insertion position of the multi-station turntable mechanism 20, and the optical camera detection component 52 is arranged above the middle of the multi-station turntable mechanism 20 and obliquely downward toward the wire insertion position.

[0033] The present invention also provides an intelligent wiring plugging method, which is implemented based on the aforementioned disc-type rotating intelligent wiring plugging device. The intelligent wiring plugging method includes the following steps.

[0034] S1. The robot grips the flat wire hairpin and moves it to the top of the wire insertion position. The turntable rotates to move the sub-tooling to the wire insertion position.

[0035] S2. The robot descends and inserts the flat wire hairpin into the assumed sub-tooling.

[0036] S3, the robot arm rises and grabs the next flat wire hairpin.

[0037] S4. Assuming that the sub-tool itself steps and rotates to the next empty wire slot, the robot moves the clamped flat wire hairpin to the top of the wire insertion position.

[0038] S5. Repeat S2-S4 until the entire circle is inserted.

[0039] S6. The turntable rotates, and the station where the full hypothetical sub-tooling is located is transferred to the wire-taking station, and the other empty hypothetical sub-tooling is transferred to the wire-insertion station to carry out a new round of wire-insertion.

[0040] This device will use advanced automation technology, combined with visual intelligent detection, to achieve automatic grasping, arrangement and insertion of flat wire coils, ensuring the accurate position and close arrangement of the coils in the stator slots. At the same time, the system will also monitor and feedback the status of the enameled wire during the plugging process in real time to avoid scratches and damage, and ensure that the plugging quality and motor performance meet the design requirements. This device is currently mainly used in the manufacture of drive motors for new energy vehicles, but it can also be expanded to other motor manufacturing fields that require efficient and precise plugging.

[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A disc-type rotating intelligent plugging device, characterized in that: The disk-type rotating intelligent wire insertion device comprises a manipulator wire insertion mechanism (10), a multi-station turntable mechanism (20), a wire insertion position lifting and rotating mechanism (30), a material picking and lifting mechanism (40), an error-proofing visual detection mechanism and a rotating wire insertion controller; the manipulator wire insertion mechanism (10) is used to clamp flat wire cards of different specifications and transport them to the top of the wire insertion position of the multi-station turntable mechanism (20); the multi-station turntable mechanism (20) is used to provide wire insertion positions of different layers in a rotating manner and receive flat wire cards provided by the manipulator wire insertion mechanism (10); the wire insertion position lifting and rotating mechanism (30) and the material picking and lifting mechanism (40) are arranged below the multi-station turntable mechanism (20) and are used to rotate and assist the upper wire insertion position in plugging or lifting to facilitate full-layer material picking; the error-proofing visual detection mechanism is arranged on the periphery of the multi-station turntable mechanism (20) and is used to monitor the line type and position of the flat wire card and realize real-time judgment and feedback of wrong insertion and missed insertion.

2. The disc-type rotating intelligent plugging device according to claim 1 is characterized in that: The robot wire insertion mechanism (10) comprises a multi-axis robot arm (11), a wire insertion lifting rod (12) and a flat wire clamp (13); the flat wire clamp (13) is mounted to the end of the vertically arranged wire insertion lifting rod (12).

3. The disc-type rotating intelligent plugging device according to claim 1 is characterized in that: The multi-station turntable mechanism (20) comprises a turntable rotating seat (21), a multi-station turntable body (22), a plurality of assumed sub-tools (23) and a tool wire taking and positioning assembly (24); a rotating switching station is fixed to the turntable rotating seat (21) and driven at the lower middle part of the multi-station turntable body (22); the plurality of assumed sub-tools (23) are arranged at the wire insertion station of the multi-station turntable body (22) and are controllably positioned by the tool wire taking and positioning assembly (24).

4. The disc-type rotating intelligent plugging device according to claim 3 is characterized in that: It is assumed that the sub-tool (23) includes a positioning groove bottom plate (232) that slides up and down in a wire insertion cage frame (231), a push plate (233) with radially evenly distributed slots and positioning fins, and a through-groove top plate (234); the positioning groove bottom plate (232) and the through-groove top plate (234) are supported and connected by an upper support column group (235); the push plate (233) is slidably arranged between the positioning groove bottom plate (232) and the through-groove top plate (234) along the upper support column group (235); a plurality of wire insertion lifting rods (236) that pass through the positioning groove bottom plate (232) are connected at the bottom of the push plate (233); and two rotating plates (238) are connected from the bottom of the wire insertion cage frame (231) to the bottom surface of the positioning groove bottom plate (232) above.

5. The disc-type rotating intelligent plugging device according to claim 4 is characterized in that: The lower ends of the plurality of wire insertion lifting rods (236) are arranged on a wire insertion lifting plate (237) and matched with the material taking lifting mechanism (40) below.

6. The disc-type rotating intelligent plugging device according to claim 1 is characterized in that: The plug-in position lifting and rotating mechanism (30) comprises a lifting and rotating gantry (31), a lifting plate (32), a lifting drive (33), a rotating drive (34), a rotating adapter (35) and a rotating profiling member (36); the four corners of the bottom surface of the lifting plate (32) are slidably mounted above the crossbeam plate of the lifting and rotating gantry (31) through a guide column assembly (37); the lifting rods of the two lifting drives (33) pass through the bottom of the crossbeam plate of the lifting and rotating gantry (31) and are connected to the two ends of the bottom surface of the lifting plate (32); the housing of the rotating drive (34) is fixed to the lifting plate (32); the end of the rotating shaft of the rotating drive (34) is connected to the rotating adapter (35), thereby driving the rotating adapter (35) and the rotating profiling member (36) to rotate as designed.

7. The disc-type rotating intelligent plugging device according to claim 1 is characterized in that: The material taking and lifting mechanism (40) comprises a material taking and lifting gantry (41), a material taking and lifting driver (42) and a lifting head (43), wherein the lifting head (43) is arranged at the end of a lifting rod of the material taking and lifting driver (42) which is telescopically extended upward.

8. The disc-type rotating intelligent plugging device according to claim 1 is characterized in that: The error-proofing visual detection mechanism comprises a light curtain sensing detection component (51) and an optical camera detection component (52), wherein the light curtain sensing detection component (51) is arranged horizontally toward a wire insertion position of a multi-station turntable mechanism (20), and the optical camera detection component (52) is arranged above the middle of the multi-station turntable mechanism (20) and obliquely downward toward the wire insertion position.

9. An intelligent plugging method, characterized in that: Smart plug-in methods include: S1. The robot grabs the flat wire card and moves it to the top of the wire insertion position. The turntable rotates to move the sub-tooling to the wire insertion position. S2, the robot descends to insert the flat wire hairpin into the assumed sub-tooling; S3, the robot arm rises and grabs the next flat wire hairpin; S4, assuming that the sub-tool itself steps and rotates to the next empty wire slot, the robot moves the clamped flat wire hairpin to the top of the wire insertion position; S5, repeat S2-S4 until the whole circle is inserted; S6. The turntable rotates, and the station where the full hypothetical sub-tooling is located is transferred to the wire-taking station, and the other empty hypothetical sub-tooling is transferred to the wire-insertion station to carry out a new round of wire-insertion.

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